Pat Roach - General Kael - intended to do the stunts by himself, but there was one thing that prevented this: "Insurance - they wouldn't let me." So horsemaster Greg Powell did the stunts for him.

Horsemaster and stuntman Greg Powell appears in person in a small role, namely as the burly redbearded Nockmaar soldier at Raziel's Lake who roughs up Madmartigan.

While filming the crossroads cage scene, Val Kilmer was being let out of the cage one day and, while he was half-way out, the chain holding up the cage broke and the cage, made of real iron, fell right on his foot, nearly breaking it. Later in the film Kilmer can be seen walking with a slight limp.

In the scene where Sorsha corners Willow and Madmartigan in the tavern, she stabs her sword point first into the floor. During one of the takes, Joanne Whalley accidentally 'planted' the sword right into the foot of one of the stuntmen at the scene. Ouch.

Several of the antagonists were named after movie critics: The villainous character of General Kael was named after the noted film critic Pauline Kael, and the unspoken name of the two-headed dragon is the Ebersisk, a reference to Roger Ebert and Gene Siskel. All of them had previously given Lucas' Star Wars saga a bad review, so you can say it's sweet revenge.

During the filming, Warwick Davis met two people who would become part of his family. His then-future wife Samantha Davis appears as a Nelwyn girl in a blue dress in the first village council scene (bottom right of the frame), and her father as the bearded Nelwyn who comforts his distressed wife after the hound's attack.

During the shooting of Airk's army's passing of the Daikini Crossroads, Gavin O'Herlihy's (Airk) horse was so restless that the cameraman had trouble keeping him in the frame. So during the close-ups O'Herlihy was actually sitting on the shoulders of horse wrangler Greg Powell.